SOLUTION FOR ENERGY MONITORING BASED ON SIDAS IEM Miroslav Dub jr., Martin Hurda, Radim Novotný
1 /36 SIDAT, spol. s r. o. (Ltd.), Zbrojnická 4/220, 162 00 Prague 6
[email protected] / www.sidat.cz
address for visitors and correspondence: Jinonická 80, 158 00 Prague 5 Maříkova 5, 621 00 Brno
We deliver complete solution for EM The solution for Energy Monitoring contains: 1. Analysis of the existing situation and a proposal of the new solution 2. Optional: Project design, delivery and installation of measurement devices for power, water, waste water, gas, steam, CO2 and pressured air. 3. Delivery and installation of “SIDAT Energy Monitoring cabinets” and network infrastructure. 4. Delivery and installation of monitoring and reporting system SIDAS IEM (developed by SIDAT). Note: Using of existing devices and reliable local suppliers is welcome
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Design of Energy Monitoring SIDAS IEM WEB PORTAL Ethernet – Information Level
SIDAS IEM SERVER WITH OPC INTERFACE
Ethernet – Production Level
CABINETS WITH PLCs AND SWITCHES AND/OR OTHER DEVICES (MEASUREMENT DEVICES, HMI/SCADA, PLC, RTDB...)
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The first implementation step Specification, definition of measurement points • What reports will be needed? • What energy types shall be measured (e.g. electricity, water, steam...) • For which branching depth/level is it purposeful to equip the distribution with measuring devices? • Which existing measuring devices may be used? Which of them need to be equipped with additional HW (e.g. communication module)? • -> “Specification” document
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List of measurement devices Přípojné místo AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1 AB1
Měřicí Umístění bod Popis signálů R0530 E033 Technologie sirupárna R0530 E076 Budova stará vodárna + vrátnice topení R0472 E034 CIP sanitace R0307 E074 Kotelna R0307 E075 Nové chladírny u kotelny R0743 E067 kanceláře CC Company R0413 E069 Telefonica O2 stanice R0376 E085 VZT call centrum 3.np - jistič R0478 E068 Eurest R0373 E086 CC Company - elektroměr pro VZT VS007 Q001 kalorimetr pro CC Company VS007 Q002 kalorimetr pro CC Company VS001 W026 voda pro AB H2-H4 S003 pára - předprodukční část - energie
VS1-2
CC01 vodivost kondenzátu ve VS1-2
AB1 AB1 AB1
H2-H4 H2-H4 H2-H4
S03Q pára - předprodukční část - průtok S03T pára - předprodukční část - teplota S03P pára - předprodukční část - tlak
AB1 AB1 AB1
VS1-2 RC001 RC001
IM01 SW01
AB1 AB1 VOD VOD VOD VOD VOD VOD VOD VOD
RC001 RC001 R0771 R0771 R0771 R0770 R0430 R0430 neoznač R1024
PC01 NT01 E011 E012 E020 E021 E030 E073 E092 W006
SIDAS IEM
armatura na páře ve VS1
SERVER EM Notebook EM vzduch doprava vzduch doprava Bag in box Linka 5 + BIB Ventilation PL2,5,6 + vodní hosp. Admin.budova 3.patro osvětlení - hala 041 voda pro výrobu - přívod
Poznámka Elektro
Požadavky na CCH
modul, struktura komunikace kontakt nový kabel JYTY, kontakt nový kabel JYTY, nový kabel JYTY, nový kabel JYTY, 24 Vdc napájení nové S-FTP od Sirec, pulsy rezerva rezerva výměna snímače,
rezerva S-FTP od Sirec, 4-20 mA S-FTP od Sirec, 4-20 mA S-FTP od Sirec, 4-20 mA nový kabel JYTY, ovládání O/C ventilu páry nový ET200S - IM151-8, 1x 8DI, 1x 2AI(4w) nový
přemístěno z R-VZD, R213, r. 2011 přemístěno z R-VZD, R213, r. 2011
nový PAC
Přenos dat Modbus TCP Modbus TCP Modbus TCP Modbus TCP Modbus TCP Modbus TCP Modbus TCP Ethernet DI+ DI+ DI+ DI+ DI+ DI+ DI+ DI+ AI 2w AI 2w AI 2w AI 2w AI 4w AI 4w AI 4w AI 4w
Adresa
DO Ethernet Ethernet
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Ethernet Ethernet Modbus TCP Modbus TCP Modbus TCP Modbus TCP Modbus TCP Modbus TCP Modbus TCP DI-
1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7
Konstanta Rozsah
10 puls / 1kWh 500 puls / 1kWh 1 puls / 1kWh 10 puls / 1kWh 10 puls / 1 m3
4/20 mA = 10÷200 μS/cm
Přípojný bod LAN dílna K - R530 dílna K - R530 dílna K - R472 chodba - R307 chodba - R307 R743 půda 4.np R413 u výtahu 3.np R0376 strojovna dílna K - R478 R743 půda 4.np VS7 - 4.np VS7 - 4.np pulsní signál, z VS1
VS1-2
W288 W290 W304 W306 rezerva do VS1-2 Rack Rack 15U
R771 R771 R771 R770 R430 R430 3.1
1 puls / 1 m3
R1024, pulsní signál
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The second implementation step Installation of missing (new) measurement devices (energy, water, CO2, air, steam): • Skilled technicians for field instrumentation and/or electro required • Important: Adjustment of distribution of electricity: planting the measurement transformers requires dismantling and remounting of power conductors… • Important : Adjustment of piping: collars...
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Power consumption – measurement devices and connection details Modbus TCP Interface (Ethernet network)
Digital Output (to PLC)
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Water/CO2 measurement consumption devices CO2 Compressed air Steam
Water
Waste water
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The third implementation step Installation of electrical and PLC infrastructure • Data backbone Ethernet network among the collection PLCs and intelligent measurement devices with Ethernet network • Installation of standardized “SIDAT energy monitoring cabinets” (SEMC) • Signal/communication cabling between the measurement devices and PLC(s) SIDAS IEM
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Network infrastructure
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SIDAT energy monitoring cabinet
PLC S7 & dig. inputs Ethernet switch Optical interface Power supply UPS Modbus TCP
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Digital output
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The fourth implementation step – SIDAS IEM installation SIDAS EM enables: • • • • • • • •
Archiving of energy data based on a selected sampling period (typically 60 sec actual data / 5 min consumption data). Displaying of actual values of energy data (reflecting the selected sampling period). Displaying of historical trends of energy data from DB Manual data entry (e.g. manual reading of data, which cannot be collected automatically). Configuration of energy tariffs and rates and cost centres Reports (reference to production data may be implemented). Interfaces to other systems (e.g. SAP-XI, historians...). Alarming; an alarm for each particular measurement/technological unit may be generated when its limit is violated.
A user may (without any interference of a programmer): • • •
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Configure measurement points (e.g. add a new one – plus the necessary changes in PLC), tariffs and rates. Configure cost centres. Configure ratio reports.
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SIDAS IEM – system structure Manual Inputs
On-line view
CLIENTS
Reports
Alarms
Configuration WEB Browser
WEB server MS SQL Server
SERVER
SIDAS DA
SIDAS BASE
OPC server interface OPCxPLC
OPC S7
OPC MDB
Cache
FIELD LEVEL (on line data)
OFF-LINE DATA
RAW DATA
Counter DI
AI
PLC S7 Standard interface (FB) SIDAS IEM
INTERFACES TO EXISTING HMI/SCADA SYSTEMS
PLC Intelligent Devices (Comm.)
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Basic requirement - to display data ON LINE VALUES
CURVES
TABLE REPORTS CHART REPORTS
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Data acquisition- configuration OPC servers configuration
OPC tags configuration
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Measurement points parameterization MP parameters
MP configuration
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Measurement points visualization MP - Actual values
MP - Trends
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Measurement points – Consumption r.
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Measurement points – Trend report
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Technology centres – parameterization TC - configuration
Devices Centres
TC - parameterization
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Basic functionality – consumption per technological centre TC - Actual values
TC - Trends
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Configuration of tariffs and rates
Tariffs configuration
Rates configuration
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Technology centres – Consumption report with costs
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Technology centres – Trend report
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Manual inputs
Forms
Tablets
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Calculated measurement points
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Virtual measurement points
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Configuration of Advanced Reporting
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Advanced reports – charts
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Advanced reports – tables
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Alarms
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Ratio report example I.
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Ratio report example II.
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Ratio report example III.
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Energy consumption recalculated to produced quantity – Example
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SIDAS IEM – selected references SIDAT implemented EM in different industry areas, e.g.: • Waste water treatment plant (ÚČOV ), Prague • PLC SIMATIC S7-400 + SIMATIC WinCC + AspenTech IP.21
• Heineken Breweries in the CZ, Krušovice and Brno • PLC SIMATIC S7-400 + ProLeiT + MS Excel
• Zlatna Panega Cement (TITAN), Bulgaria • SIMATIC PCS7 + SIMATIC IT Historian + MS Excel
• Yoghurt plant Danone, Benešov • PLC SIMATIC S7-400 + Intouch + InSQL
• Coca Cola, Prague • PLC SIMATIC S7-ET200S
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